Rough-in Box for Creating Penetrations in Poured Concrete Flooring and Method of Use

ABSTRACT

A rough-in box kit ( 100 ) for creating a rough-in box ( 200 ) to create a penetration in poured concrete flooring during the construction of concrete buildings. The rough-in box kit ( 100 ) includes a single unitary piece ( 1 ) having a flat section ( 5 ) with: a top end; a bottom end opposite to the top end; an inside surface ( 5   a ) located between the top end and the bottom end, and configured to form an inside surface of the rough in box ( 200 ); and an outside surface ( 5   b ) opposite to the inside surface ( 5   a ), and configured to form an outside surface of the rough in box ( 200 ). The single unitary piece ( 1 ) also has a top flange ( 3 ) connected to and extending away from the top end of the flat section ( 5 ), and perforations, through-holes, or slots ( 2 ) that are formed in the flat section ( 5 ). The single unitary piece ( 1 ) is configured to be bent at locations corresponding to and lining up with the perforations, through-holes, or slots ( 2 ) so as to form the rough-in box ( 200 ).

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates generally to a rough-in box for creatingpenetrations in poured concrete flooring during the construction ofbuildings, and a method of using the device.

2. Background

Currently there are a number of solutions for creating penetrations inconcrete slabs during the construction of buildings. The penetrationsmay then be utilized for the installation of plumbing, ducts, mechanicalsystems on or between floors, for construction access, or any otherpurpose a penetration may be used. One method to install plumbing ormechanical systems through concrete floors is by cutting or chopping outholes in the floor or drilling such holes after the concrete floor hasbeen placed. These holes are then used the as access for pipes, ducts,conduits or any other purpose a penetration may be used. This solutionfails to meet the needs of the industry because it is time consuming,labor intensive and wasteful of construction material and results indamage to the structure of the building.

Another solution to provide slab penetrations includes the on-sitefabrication of plywood boxes. The plywood boxes are constructed so as tobe placed on the formed deck and exclude concrete from the box (i.e.,concrete is poured around the box,) thus providing a penetration. Theuse of this method creates several undesirable conditions. First, theplywood boxes must be stripped from within the concrete slab afterconcrete placement for fire safety reasons. This stripping requiresadditional labor, generates hazardous debris, and the work of strippingis itself a hazardous activity. Second, after the concrete is placedholes must be covered with plywood. These covers are raised from thefloor surface and therefore constitute a tripping hazard. The raisedplywood covers also interfere with the use of any wheeled conveyancessuch as manlifts, pallet jacks, and carts. Plywood covers are alsoeasily accidentally displaced during subsequent construction activities.This creates both a fall hazard for workers on the floor above thepenetration and exposes workers below to objects falling from the floorabove. Additionally, plywood covers have relatively limited strength,and this strength can be further diminished as plywood is subject todeterioration when exposed to water and other environmental conditions.

Another application where voids must be provided in concrete slabsoccurs when plumbing fixtures require voids or penetrations in theconcrete slab. These voids are typically formed by use of steel boxesthat are set prior to placing concrete. But these steel boxes are notdesigned to be left in place, and instead designed to be reused fromfloor to floor. Because these steel boxes need to be reused onsubsequent floors, they must be removed quickly once the concrete hasjust set but has not developed full strength. This requires workers towalk on fresh concrete which can leave footprints and other indentationsin the newly placed slab which must be repaired. Also, the act ofremoving the boxes often damages the concrete at the edges of the voidrequiring costly repair work. Similar to the penetrations discussedabove, these voids must be covered with plywood. These plywood coversare subject to the same problems and hazards cited in the paragraphabove.

None of the forms described above are suitable for bearing the weight ofworkers and construction vehicles/equipment/materials without creatingan uneven floor surface that constitutes a tripping hazard forconstruction workers and which could hinder the movement of wheeleddevices. Moreover, none of the forms described allow construction tocontinue without the need to remove or trim the forms or covers placedover the forms before the placing of concrete. Further, the strength ofcovers currently in use are typically unable to support heavy loads withappropriate safety factors and are subject to deterioration due toenvironmental conditions and removal and misplacement due toconstruction activities.

The typical current method of creating penetrations and voids inconcrete floors during the construction of buildings involves using jobplywood boxes or removable metal boxes generally includes the followingsteps:

-   -   (1) The boxes are lifted and placed by crane on the floor that        is being readied to be poured.    -   (2) The boxes are then carried and placed on the prearranged        spots on the deck. Depending on the size of the box this may        require two workers.    -   (3) The box is tied to the rebar or fastened to the deck to        prevent the box from being moved or dislodged during the        concrete placement.    -   (4) Steel plumbing void forms are greased to facilitate removal        from concrete.    -   (5) The concrete is placed to create the slab.    -   (6) The surface is screeded and trowelled to make it flat and        level.    -   (7) Steel plumbing void forms are removed by prying from the        slab after the concrete is set but not fully hardened. This        process usually takes two workers. This process can cause damage        to the surface of the concrete with footprints and also to the        edges of the hole.    -   (8) The surface of the concrete must be repaired to remove the        footprints and fix other surface damage resulting from removal        of the boxes.    -   (9) During the pouring process, some concrete often overflows        into the boxes, and when the boxes are removed the hardened        concrete has to be removed from the box. This cleaning process        requires two workers to strike the box sides with sledgehammers        to loosen the concrete and then chip out the remainder with a        scraper or chisel.    -   (10) Plywood penetrations boxes are stripped and removed when        the deck below the concrete floor is stripped, creating        additional debris and hazards.    -   (11) Debris from plywood boxes and steel plumbing boxes is        gathered and removed from the site    -   (12) Before the supports and formwork for the next floor can be        erected, the open holes must be covered to prevent injuries.        Plywood covers are placed over the hole and nailed to the        concrete to act as a cover.

This method does not meet the needs of the industry because it has manyinherent problems and inefficiencies, some of which are now discussed.

While formwork for the next floor are ongoing, stripping of formwork onthe floor below begins. This process involves heavy traffic on the floorand often covers can be displaced. This creates hazardous conditions forthe workers and leads to increased labor to repair and replace covers.

Once the plumbing, mechanical, or other penetrations in one floor arecovered, the erection of the support legs and deck form for the nextfloor can begin. During the normal course of construction activities theplywood hole covers can become dislodged and sometimes discarded. Toprevent injuries caused by stepping through a hole or items falling onworkers below, covers must be replaced or refastened to the floor. Thisis a constant maintenance item and it requires the ongoing expenditureof labor hours.

The concrete contractor must maintain the covers for approximately sixfloors until the general contractor assumes control of the floor.Maintenance typically consists of daily inspections of the penetrationcovers on each floor to ensure they are still correctly positioned andfastened to the floor, and refastening loose covers. Once the generalcontractor takes control of the floor they generally remove the concretecontractor's covers and replace them with a double plywood cover withchamfered sides The old covers then need to be removed from the floorand discarded. The new covers have many of the same disadvantages thatthe previous covers had.

It would be desirable to have a device and method of using the device toform an opening in concrete slab during the placement of concrete whichis capable of providing an upper surface that is flush with the concretefloor, has the strength to support the weight of workers andconstruction supplies, can remain in place after construction, and haswaterproofing and fireproofing capabilities. This would eliminate theneed to cover openings with plywood, which creates a tripping hazard forconstruction workers and impedes the movement of wheeled carts andtrucks that are used to move materials around the construction site.Still further, it would be desirable to have a device and method thatprovides for improved efficiency, increased safety, and reduced laborcosts. Therefore, there currently exists a need in the industry for adevice and associated method that provides for an opening in pouredconcrete flooring, with an upper surface that is flush with thesurrounding floor, strong enough to support the weight of constructionmaterials and workers, waterproof, fireproof, and cost effective.Therefore, there currently exists a need in the industry for a deviceand method of use that solves all the problems discussed above.

Specifically there is a need for a form that can be used to enablepenetrations to be created in a concrete floor while concrete for thefloor is being poured, that can permit work on the floor to continuewithout the need for removal of materials and which can remain in placeeven after the floor is completed, that provides a fireproof andwaterproof barrier, and that desirably can easily accommodate differentsized penetrations.

SUMMARY OF THE INVENTION

The present invention advantageously fills the aforementioneddeficiencies by providing a rough-in box for creating penetrations inconcrete flooring along with a method of use which creates a penetrationin the flooring while providing a flush surface with the floor which cansupport the weight of workers and equipment, can remain in place postconstruction, and provides waterproofing and fire proofing capabilities.The present invention further provides a method using such boxes.

The present invention provides a structure for forming openings inpoured concrete slab flooring, which is made up of the followingcomponents: one or more boxes, for example two boxes, forming an openingof a desired shape. Rectangular side walls can be used for forming a boxhaving the shape of a rectangular prism, and curved side walls can beused for forming a circular or elliptical box.

In a particularly useful embodiment, each box has four sides, and anoptional top lid. The top lid is strong enough to permit workmen andtheir equipment to move across it without risk. The strength required ofthe top depends on the particular situation in which the box is beingused. Conveniently, the box is formed on site from pre-formed sidepieces. It is desirable that the top piece is customized for aparticular location. To facilitate on-site assembly of a box, the sidepieces are designed to be easily bent to the preferred configuration. Aflange is provided at the top of the side profile which serves tosupport the top of the box flush with the concrete. This configurationis typically used for ducts and other mechanical systems that govertically from floor to floor, but is equally applicable to any slabopening that must be protected during construction.

In another embodiment, typically used to form a void for the connectionof plumbing fixtures on a floor, one or several boxes can be configuredto accommodate the required void. In plan view these boxes may take alinear shape, the shape of the letter T or L, or a cruciform shape.Where the sides of the boxes abut, there will be an opening in the wallof each box to allow access between the two boxes for subsequentplumbing installation. The top side of each box will be removable. Whenthe desired configuration has been created, the device is placed in therequired position on the deck of the floor. Concrete is poured onto thedeck and cured. The top sides of the boxes will sit flush with the floorsurface to allow for pallet jacks and other wheeled carts to be movedover the covered openings without hindrance and without the need forplywood coverings which create tripping hazards.

While the above embodiment describes multiple rough-in boxes being usedto create a given shape, it should be appreciated that the same shapecould be formed by connecting multiple rough-in box kits to form asingle rough-in box with one of the above-mentioned shapes.

Another embodiment of the present invention will serve as a hole coverfor penetrations that have been conventionally formed in a concrete slabor any hole in any floor that needs to be covered securely. In thisembodiment, as shown in FIGS. 17-19, a frame of bent steel sections 12is fastened in the opening and provided with a top lid 6 with sufficientstrength to allow construction activities to safely proceed.

In still another embodiment of the present invention a steel frame ismade to mount over steel pour stops typically used in steel framedbuildings where the slabs are placed on top of metal deck forms. Thissteel frame is fitted with a lid of sufficient strength to allowconstruction activities to safely proceed. This version of the inventionis suitable for steel framed buildings and provides a flush hole cover.

The present invention may also have one or more of the following. Theboxes may be constructed to be water tight to prevent water travelingthrough the floor penetration. The boxes may be constructed entirely orpartially of a fireproof material. The boxes may also incorporateintumescent material as a means of fireproofing the penetration.Similarly, the method associated with the present invention may alsoinclude one or more of the following steps: installing waterproofingdevices, installing fireproofing devices.

The present invention is unique when compared with other known devicesand solutions because the invention provides a structure: (1) whichcreates a slab pass-through and a void space for plumbing, mechanical,or other access and which can remain in place after the concrete cures(2) which optionally has a closed top that is flush with the slab floorand can support the weight of construction workers and material; (3) andwhich optionally provides waterproofing and fireproofing protection.Similarly, the associated method is unique in that it: (1) eliminatesthe time and labor of constructing and installing wooden covers on-site;(2) eliminates the time and labor removing forms from cured concrete;and (3) eliminates obstructions and tripping hazards at the constructionsite.

The present invention is unique in that it is structurally differentfrom other known devices or solutions. More specifically, the presentinvention is unique due to the presence of: (1) a top lid which is flushwith surrounding concrete and significantly stronger than currentmaterials: (2) rectangular or square shaped structures for both the passthrough section and plumbing connector as well as full penetrationsections for shafts or mechanical systems; and (3) rigid constructionthat can support the weight of workers and material. Furthermore, theprocess associated with the aforementioned invention is likewise uniqueand different from known processes and solutions. More specifically, thepresent invention process owes its uniqueness to the fact that itachieves as good or better results than conventional methods in fewersteps, less time, less labor, less cost, and has safety advantages.

Among other things, it is an object of the present invention to provideplumbing boxes and mechanical boxes for creating penetrations inconcrete flooring and methods of use that does not suffer from any ofthe problems or deficiencies associated with prior solutions.

It is still further an objective of the present invention to create adevice that is more economical to produce, easier to manufacture, easierto ship to the work site, easier to install and of sufficient durabilityto remain in place after construction is complete.

Further still, it is an objective of the present invention to create adevice that is amenable to mass production in a variety of standarddimensions frequently encountered in the industry, thereby enabling thedevice to be more easily commercialized.

In a preferred aspect of the present invention, the boxes are comprisedof components that allow accurate on-site bending at increments thatallow easy field fabrication of appropriate size rough-in boxes for thedesired penetrations. Typically, the components forming the side wallsof the box and are bent into shape as described below. The tops of thesewall members provide a flange on which the cover may be placed.

The side walls may be formed of any strong, tough material which mayvary in accordance with the particular application or circumstancesunder which the rough-in box is to be used. For example, the side wallsmay be made from metal alloys, fiberglass, and heavy duty plastics, orany combination thereof. Examples of heavy duty plastics includepolyethylene, polyvinyl, and polypropylene. In one particularembodiment, the side walls are made from an aluminum alloy, such as thealuminum 5000 series, and may have a thickness in the range of 0.03 to0.1, for example, 0.050 inches. In another embodiment, the side wallsare made from galvanized steel (e.g., 22 ga galvanized steel). Otherproperties such as weight can be relevant to the choice of material forthe side walls of the rough-in box.

The top lid needs to be strong enough to provide a working surface onthe floor while construction is being carried out. As such, the top lidmust be capable of supporting a concentrated weight of approximately2,000 pounds and a uniformly distributed load of approximately 100pounds per square foot. The lid can be made from a broad range ofmaterials including fiber reinforced plastics, engineered wood, or heavyduty plastics, or a combination thereof. In one embodiment, the top lidcan be made of resin impregnated fiberglass with the density of fibersbeing determined by the weight that the closure has to bear. Generally,the number of piles or layers of fibers will affect the flexuralstrength of the lid as will be further discussed below. The resins usedto impregnate the fiberglass may include epoxy resins as well as othertypes of thermosetting plastics such as polyester or vinyl-ester resinsand thermoplastics. The lids may be custom made to have a fixed size forparticular sized penetrations. If required, the lid can be supported byone or more struts stretching across the box from an opening or verticalslot in one wall to an opening or vertical slot in the opposite wall.

In another aspect, the present invention provides a method forconstructing a floor containing penetrations which comprises: assemblingthe walls of a box as described above, locating such boxes on a floordeck, placing a lid being made of a material stronger than that of thesidewalls and being capable of supporting a weight of approximately2,000 pounds on the top of said box, pouring concrete to form a flooraround said boxes, performing work on said floor after pouring theconcrete, and subsequently removing said top, leaving the remainingparts of the box in situ in the concrete, and installing plumbing orelectrical fittings within said box.

In a further embodiment, the walls of the box, irrespective of whetherthe walls are a fixed size or the wall lengths are adjustable, areprovided with one or more grooves into which fire proofing or fireretardant can be injected or inserted.

In a yet further embodiment of the invention, the box components or thelid are provided with elements from which a guard rail may be providedto surround the perimeter of the penetration.

To comply with safety regulations, the upper surface of the lid shouldbe a bright color (yellow and orange being typical) and should beprovided with a non-slip upper surface and be clearly marked with theword “HOLE”.

In a preferred embodiment, the box may be made to the required size bybending a single unitary piece along lines of perforations located atincrements along the single piece.

In one embodiment of the invention there is provided a rough-in box kit(100) for creating a rough-in box (200) to create a penetration inpoured concrete flooring during the construction of concrete buildings.The rough-in box kit (100) includes a single unitary piece (1) having aflat section (5) with: a top end; a bottom end opposite to the top end;an inside surface (5 a) located between the top end and the bottom end,and configured to form an inside surface of the rough in box (200); andan outside surface (5 b) opposite to the inside surface (5 a), andconfigured to form an outside surface of the rough in box (200). Thesingle unitary piece (1) also has a top flange (3) connected to andextending away from the top end of the flat section (5), andperforations, through-holes, or slots (2) that are formed in the flatsection (5). The single unitary piece (1) is configured to be bent atlocations corresponding to and lining up with the perforations,through-holes, or slots (2) so as to form the rough-in box (200).

In another embodiment, the top flange has a first extension (3 a) thatextends from the flat section (5) at approximately a 90° angle, and asecond extension (3 b) that extends from the first extension (3 a) atapproximately a 90° angle.

In yet another embodiment, the perforations, through-holes, or slots (2)are formed in the first extension (3 a).

In a further embodiment, the perforations, through-holes, or slots (2)are not formed in a distal end of the second extension (3 b) opposite toand distal from the first extension (3 a).

In yet a further embodiment, the perforations, through-holes, or slots(2) are formed in a proximal end of the second extension (3 b) adjacentand proximal to the first extension (3 a).

In another embodiment, the perforations, through-holes, or slots (2) arenot formed in any portion of the second extension (3 b).

In yet another embodiment, wherein the single unitary piece (1)additionally has a bottom flange (4) connected to and extending awayfrom the bottom end of the flat section (5) opposite to the top end ofthe flat section (5).

In a further embodiment, the bottom flange extends from the flat section(5) at approximately a 90° angle.

In yet a further embodiment, the single unitary piece (1) additionallyhas a bottom flange (4) connected to and extending away from a bottomend of the flat section (5) opposite to the top end of the flat section(5). The bottom flange (4) extends approximately parallel to the a firstextension (3 a) of the top flange (3).

In another embodiment, the perforations, through-holes, or slots (2) arenot formed in a distal end of the bottom flange (4) opposite to anddistal from the flat section (5).

In yet another embodiment, the perforations, through-holes, or slots (2)are formed in a proximal end of the bottom flange (4) adjacent andproximal to the flat section (5).

In a further embodiment, the perforations, through-holes, or slots (2)are not formed in any portion of the bottom flange (4).

In yet a further embodiment, the perforations, through-holes, or slots(2) form vertical arrays (2 a) in the flat section (5), each verticalarray (2 a) extending in a vertical direction from the top end to thebottom end of the flat section (5).

In another embodiment, the vertical arrays (2 a) of perforations,through-holes, or slots (2) are spaced apart from each other in ahorizontal direction perpendicular to the vertical direction so that theperforations, through-holes, or slots (2) additionally form horizontalarrays (2 b) in the flat section (5) extending in the horizontaldirection.

In yet another embodiment, the singe unitary piece (1) made of analuminum alloy.

In a further embodiment, the rough-in box kit (100) further includes alid (6) formed configured to supporting a weight of at leastapproximately 2,000 pounds when placed on top of the formed rough-in box(200).

In yet a further embodiment, the lid (6) is formed of resin-impregnatedfiberglass.

In another embodiment, the resin-impregnated fiberglass is impregnatedwith an epoxy resin.

In yet another embodiment, the lid (6) comprises 18 to 40 fiberglasslayer strands of fiber.

In a further embodiment, there is provided a rough-in box (200)including the rough-in box kit (100) where the single unitary piece (1)is bent at locations corresponding to and lining up with theperforations, through-holes, or slots (2) so as to form the rough-in box(200) with the lid (6) being flush with a poured concrete floor.

In yet another embodiment, the rough-in box (200) further includes aseal arranged between the lid (6) and the top flange (3) to create awaterproof or water-resistant seal when the lid (6) is arranged on thetop flange (3).

In another embodiment, there is provided a method of constructing apenetration in a concrete floor (300). The method includes bending thesingle unitary piece (1) of the rough-in box kit (100) of one of claims1-19 at locations corresponding to and lining up with the perforations,through-holes, or slots (2) so as to form a rough-in box (200). Then therough-in box is placed (200) in a location on a formed deckcorresponding to a predetermined location for the penetration in theconcrete floor (300). Next, concrete is poured around the rough-in box(200) to form the concrete floor (300).

In yet another embodiment, there is provided a method of constructing apenetration in a concrete floor (300). The method includes bending asingle unitary piece (1) so as to form a rough-in box (200). Then therough-in box (200) is placed in a location on a formed deckcorresponding to a predetermined location for the penetration in theconcrete floor (300). Next a lid (6) is placed on top of the rough-inbox (200). After that, concrete is poured around the rough-in box (200)to form the concrete floor (300).

In a further embodiment, one end (8 a) of the single unitary piece (1)is secured and affixed to an opposite end (8 b) of the single unitarypiece (1) to form the rough-in box (200).

In yet a further embodiment, the method further includes cutting a topflange (3) of the single unitary piece (1) at multiple first locations,and cutting a bottom flange (4) of the single unitary piece at multiplesecond locations. The single unitary piece (1) is then bent alongmultiple bending lines (18) so as to form a rough-in box (200), eachbending line (18) extending from one of the first locations to one ofthe second locations.

In another embodiment, each bending line (18) corresponds to an array ofperforations, through-holes, or slots (2) single unitary piece (1) sothat the single unitary piece (1) is bent along the arrays ofperforations, through-holes, or slots (2).

In yet another embodiment, the concrete is poured around the rough-inbox (200) to form the concrete floor (300) so that the lid (6) is flushwith the poured concrete floor.

In a further embodiment, there is provided a kit for a platform tosecurely hold a lid (6) over a penetration in a concrete floor (300).The kit includes multiple single unitary pieces (12), each having afirst extension (12 a) extending along a first plane, a second extension(12 b) extending from an end of the first extension (12 a) along asecond plane intersecting with the first plane, and a third extension(12 c) extending from an end of the second extension (12 b) opposite tothe first extension (12 a) along a third plane approximately parallel tothe first plane.

In yet a further embodiment, a height of the second extension (12 b)extends between the first and third extensions (12 a, 12 c) in adirection perpendicular to the first plane corresponds to a thicknessdimension of a lid (6).

In another embodiment, at least one of the first and third extensions(12 a, 12 c) includes through holes (19), each through hole (19) beingconfigured to accept a screw or bolt (13) so that the multiple singleunitary pieces (12) can be screwed or bolted to the concrete floor(300).

In another embodiment, there is provided a platform for securely holdinga lid (6) over a penetration in a concrete floor (300). The platformincludes the multiple single unitary pieces (12). Each single unitarypiece (12) is arranged around an edge of the penetration so that atleast a portion of an end (12 d) of each single unitary piece (12)overlaps with at least a portion of an end (12 d) of an adjacent singleunitary piece (12).

It is noted that the features of the above-described embodiments are notexclusive to each other, and that any one of the aboveembodiments/features can be combined with one or more of the otherembodiments/features to arrive at further embodiments.

The present invention will now he described more fully hereinafter withreference to the accompanying drawings, which are intended to be read inconjunction with both this summary, the detailed description, and anypreferred and/or particular embodiments specifically discussed orotherwise disclosed. This invention may, however, be embodied in manydifferent forms and should not be construed as limited to theembodiments set forth herein. Rather, these embodiments are provided byway of illustration only so that this disclosure will be thorough,complete, and will fully convey the scope of the invention to thoseskilled in the art.

BRIEF DESCRPTION OF THE DRAWINGS

FIG. 1 shows an embodiment of the rough-in box 200 along with basiccomponents of the box (single unitary pieces 1 and lids 6) as they willbe provided to a job.

FIG. 2 shows a perspective view of the side profile of a single unitarypiece 1 of kit 100 for a rough-in box 200 in an unassembled state. Thissingle unitary piece 1 can be provided in various lengths to suit theapplication.

FIGS. 3a and 3b show the method by which the single unitary piece 1 iscut in specific locations so that it can be bent into the box shaperequired for the application.

FIG. 4 shows the side profile of the single unitary piece 1 with asingle 90 degree bend.

FIG. 5 shows an embodiment of a the side profile of the single unitarypiece 1 with a 90 degree bend.

FIG. 6 shows the side profile of the single unitary piece 1 with asecond 90 degree bend.

FIG. 7 shows the single unitary piece 1 side profile with the top andbottom flanges 3, 4 partially trimmed at one of the two ends 8 a, 8 b(e.g., left end 8 a in FIGS. 7-9) and the resulting tab 11 bent at 90degrees ready to overlap and attach to the other opposite end 8 a, 8 bof the single unitary piece 1 to form a closed box.

FIG. 8 shows the tab 11 referenced in FIG. 7 overlapping the oppositeend of the single unitary piece 1 so that the opposite ends of thesingle unitary piece 1 (in this case the tab end and the opposite end)are ready to be attached to each other by screws 13 or other means.

FIG. 9 is a perspective view of the single unitary piece 1 bent into acompleted rectangular rough-in box 200.

FIG. 10 shows the completed box 200 with a lid 6 attached, with anenlarged a detail showing an optional corner piece 10 that may beapplied to protect the corner of the lid.

FIG. 11 shows a completed rough-in box 200 with optional corner pieces10 and a lid 6 with a handle 9.

FIG. 12 shows a lid 6 being installed onto the top of the completedrectangular rough-in box 200.

FIG. 13 shows a plan view of the rough-in box 200 completed without thelid 6.

FIG. 14 shows a side view of the completed rectangular rough-in box 200.

FIG. 15 shows a side view of the rough-in box kit 100 in FIG. 2 along anend of the kit.

FIG. 16 shows cross sectional view of part of the rough-in box 200 afterconcrete has been poured.

FIG. 17 shows cross sectional view of one of the steel sections 12 ofFIG. 18.

FIG. 18 shows a plan view of a version of the invention designed tocover a hole in an existing slab. This is comprised of steel sections 12surrounding the perimeter of the hole fastened to the surrounding slabthat support a cover.

FIG. 19 a perspective view of one of the steel sections 12 of FIG. 18.

FIG. 20 shows examples of fire rated rubber seals 14.

FIG. 21 shows a non-slip or slip resistant surface 15.

FIG. 22 shows a lid 6 with hydraulic hinges 16.

FIG. 23 shows an example of a handle 9 for the lid 6.

FIG. 24 shows examples of the different types of screw heads that can beused to effectively lock the lid 6 to the rough-in box 200.

FIGS. 25 and 26 show an optional deployable safety rail system 17.

FIG. 27 is a plan view of the metal rough-in box 200 in place.

FIG. 28 shows a cross-section through the metal rough-in box 200 withthe concrete deck poured.

FIG. 29 shows a cross-section through the metal rough-in box 200 priorto concrete placement.

FIG. 30 is a plan view of a configuration 400 of multiple single unitarypieces 1 attached together to form a frame for a single depression ofpenetration.

FIG. 31 is a cross sectional view through line A-A of the configuration400 of FIG. 30.

FIG. 32 is a side view of the configuration 400 in FIG. 30.

FIG. 33 shows an embodiment with a slot 46 in the side walls of therough-in box 200 to receive expandable foam fireproofing.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a mechanical rough-in and plumbingbox 200 for creating penetrations in concrete flooring and a method ofuse.

FIG. 1 shows that these components—single unitary pieces 1 and lids6—are capable of being flat packed such that they fit together whenstacked on top of one another. This saves space when transporting andstoring the components. Thus, the components can be delivered with fewertrucks, and take up less storage space at the jobsite.

In the embodiment of the present invention in FIG. 2, the rough-in box200 is formed from a single unitary piece 1, which can be supplied in asingle stock length to form rough-in boxes 200 of differing sizes anddimensions. The single unitary piece 1 is supplied with perforations,through-holes, or slots 2 in increments across their width. By snippingthe top and bottom flanges 3, 4 of the single unitary piece 1 atlocations corresponding to and lining with the perforations,through-holes, or slots 2, the profile may be bent or cut at any of theincremental lengths that correspond to the spacing of the perforations,through-holes, or slots 2, as shown in FIG. 3 and further shown in FIGS.4, 5, 6, and 7. This feature allows the single unitary piece 1 to beformed into virtually any shape by varying the lengths between the bendsand the angle of bends. The profile is fastened into a closed shape bytrimming a short length of the flanges 3, 4 of one end 8 a, 8 b (e.g.,left end 8 a in FIGS. 7-11) of the single unitary piece 1 to form a tab11, and then bending the resulting tab 11 (FIG. 7) to match the oppositeend 8 a, 8 b (e.g., right end 8 b in FIGS. 7-11) of the single unitarypiece 1 and securing the two ends 8 a, 8 b by screws 13 or some othermeans. Should the shape of the desired rough-in box 200 exceed thelongest length of the single unitary piece 1 supplied, a second singleunitary piece 1 can be spliced to the first in a manner similar to thatdescribed above wherein a tab 11 is created by trimming the flanges 3, 4of the piece 1 allowing the end 8 a, 8 b of one piece 1 to lie flat onthe corresponding opposite end 8 a, 8 b of the second piece 1. Thepieces 1 can then be spliced or affixed together with screws 13 or otherappropriate means.

Preferably, the perforations, through-holes, or slots 2 are formed alongvertical arrays 2 a from the top of the single unitary piece 1 to thebottom of the bottom of the single unitary piece 1. This allows thesingle unitary piece 1 to be bent along straight lines to form thecorners of the rough-in box 200. The vertical arrays 2 a are spacedapart from each other at fixed increments along the width of the singleunitary piece 1. Preferably the distance between adjacent verticalarrays 2 a is constant. In one embodiment, the constant distance betweenthe vertical arrays 2 a is from 0.5 inches to 6.0 inches. Preferably,the constant distance between the vertical arrays 2 a is from 0.5 inchesto 3.0 inches. More preferably, the constant distance between thevertical arrays 2 a is from 0.5 inches to 2.0 inches. Most preferably,the constant distance between the vertical arrays 2 a is from 0.5 inchesto 1.5 inches. In a particularly preferred embodiment, the constantdistance between vertical arrays 2 a is approximately 1.0 inches.

In another embodiment, the vertical arrays 2 a of perforations 2 arespaced so that the perforations 2 also line up with each otherhorizontally to form horizontal arrays 2 b that are perpendicular to thevertical arrays 2 a.

Preferably, each perforation, through-hole, or slot 2 is formed in anoval or rectangular shape with its longest dimension extending along thesame direction of the vertical array 2 a in which it is arranged. Thisfurther facilitates bending the single unitary piece 1 to form therough-in box 200.

The single unitary piece 1 consists of a flat section (web) 5, a topflange 3 which is shaped to support the box lid 6 flush with the surfaceof the concrete 300 (see FIG. 16), and a lower flange 4 that enhancesthe strength of the single unitary piece 1 and allows the finished box200 to be securely fastened to the deck form. The flat section (web) 5has an inside surface 5 a and an outside surface 5 b, with the insidesurface 5 a forming an inside surface of the final rough-in box 200 andthe outside surface 5 b forming an outside surface of the final rough-inbox 200.

The rough-in box 200 is formed by snipping the flanges 3, 4 at locationscorresponding to the perforations, through-holes, or slots 2, andbending the single unitary piece 1 along the perforations,through-holes, or slots 2 as required to attain the finished shapedesired. Once the shape is attained the box 200 is fastened by securingthe web tab 11 from one end 8 a, 8 b of the profile to the opposite end8 a, 8 b.

In one embodiment, the profile of the rough-in box may be snipped andbent at very small intervals thereby creating a chorded circular shape.

There is no need to have a bottom surface on the rough-in box 200 asthat would hinder the installation of plumbing, ducts, or othermechanical systems between floors. Thus, only a lid 6 needs to be openedso that these systems can be passed up from the floors below.

Once the side walls 7 of the rough-in box 200 are formed and the ends 8a, 8 b joined together, the lid 6 is attached to the rough-in box 200.Each side wall 7 of the rough-in box has a top flange 3 to providesupport for the lid 6 so that the lid 6 can is supported by each of theside walls 7 of the rough-in box 200.

The lid 6 is load bearing to permit workmen, equipment, vehicles, andmaterials to move over the lid 6 without risk of the lid 6 collapsingand caving in. Therefore, the lid 6 needs to be made from a strongenough material to provide a working surface on the floor whileconstruction is being carried out. In one embodiment, the lid 6 isdesigned to support a weight of at least approximately 2,000 poundsconcentrated load and approximately 200 pounds per square foot uniformload. The lid 6 can be made from fiberglass or from heavy duty plasticssuch as polyethylene, polyvinyl, and polypropylene. Additionally, insome embodiments, the lid 6 can be made from engineered wood. It is alsopossible that the lid 6 is made from a combination of fiberglass, heavyduty plastic, and/or engineered wood.

In one embodiment, the lid 6 can be made from resin impregnatedfiberglass with the density of fibers being determined by the weightthat the lid 6 has to bear. The resins used to make the lid 6 caninclude epoxy resins as well as other types of thermosetting plasticssuch as polyester or vinyl-ester resins and thermoplastics.

A fire rated rubber seal 14, such as the one shown in FIG. 20, can beadded to the lid 6 for water resistance. The shape of the seal 14 shouldcorrespond to the shape of the lid 6 so that the seal 14 added to theunder surface of the lid 6 of the rough-in box 200 to create a tightseal with the top flange 3 of the side walls 7 when the rough-in box 200is closed. Waterproofing the rough-in box 200 allows sheetrock and otherwater-sensitive materials to be stored on floors below without worry ofdamage.

Optionally, compressed fireproofing can be embedded into the side walls7 of the rough-in box 200. As shown in FIG. 33, a slot 46 can be leftinto the side walls of the rough-in box 200 to receive expandable foamfireproofing. Alternatively, an expandable fireproofing material—forexample, expandable foam fireproofing material—can be affixed to theinside surface 5 a of the single unitary piece 1 which will form aninside surface of rough-in box 200. After the rough-in box 200 isassembled and put into place, a worker can pull off a tape that willexpose the expandable fireproofing material (e.g., expandable foamfireproofing). When the tape is removed, the fireproofing material willexpand until it meets a solid barrier—for example, air conditionerducts—such that when a duct is passed through the rough-in box 200, thefireproofing material is adhered to the surface of the duct. Thefireproofing material can be an intumescent tape or any equivalentthereof. Intumescent materials that can be included in the tape include,for example, polyphosphates (such as ammonium polyphosphate) andmaterials that react with such phosphates such as pentaerythritol andmelamine, or silicate-containing materials

If desired, the lid 6 can be supported by a strut (not shown) stretchingacross the box from an opening or vertical slot in one wall to anopening or vertical slot in an opposite wall to provide additional loadbearing strength.

As shown in FIG. 22, the lid 6 may be equipped with hydraulic hinges 16to control the speed at which the lid 6 opens and also to keep the lid 6in a vertical open position when the lid 6 is opened by a worker workingon the hole.

The lid can also be equipped with a lanyard or tether 20. The lanyard ortether 20 will provide positive attachment between the lid and the sidewalls of the box. The lanyard or tether 20 will allow lids to be removedbut will insure that the lid is not removed from the immediate area ofthe opening.

The lid 6 can feature a grip and/or handle 9 for easy opening of the lid6. An example of a handle is shown in FIG. 23.

Different locks/screw heads can be utilized to secure the lid 6 to therough-in box 200 so that only certain personnel from a particular tradecan open the rough-in box 200. For example, some designated rough-inboxes 200 can be equipped with a special screw head that can only beopened by plumbers, whereas other designated rough-in boxes 200 can beequipped with a different screw head that can only be opened byelectricians. Examples of the different types of screw heads that can beused to effectively lock the lid 6 to the rough-in box 200 are shown inFIG. 24.

As a safety measure, the top side of the lid 6 can have a non-slipsurface 15 so that workers and equipment moving over the lid 6 do notslip when crossing the rough-in box 200. A slip resistant surface thatcan be applied to the lid 6 is shown in FIG. 21.

As shown in FIGS. 25 and 26, the lid 6 can also be equipped with adeployable safety rail system 17 as an additional safety measure. Thedeployable safety rail 17 is a series of tubular members that areconnected together and fastened to the rough-in box 200 and the lid 6when the lid 6 is open to prevent accidental trips and falls due to thehole being open. The deployable safety rail 17 can becollapsed/de-constructed and stored in pieces within the rough-in box200 on the underside 6 a of the lid 6 for storage as shown in FIG. 25.When deployed, the tubular pieces of the safety rail 17 are removed fromthe underside of the lid 6, and are then assembled together atop therough-in box 200 to form a rectangular prism that would prevent a workerfrom falling inside the hole of the rough-in box 200 when the lid 6 isopen as shown in FIG. 26. The presence of the deployed safety rail 17also acts as a warning to workers walking on the construction site thatthe lid 6 of the rough-in box 200 is open.

A sensing system that would alert workers and staff on the jobsite as towhen a particular rough-in box has been left open can be included in therough-in box 200. For example, a pressure sensor can be integrated intothe lid 6, side walls 7, or both the lid 6 and side walls 7 of therough-in box 200. When the lid 6 is closed, the sensor will register theapplied pressure. When the lid 6 is open, no pressure will be detectedby the sensor, and the sensor will then wirelessly relay to a visualdisplay that the rough-in box 200 is open.

When installing the rough-in box 200, a numbering system can be usedsuch that each box is numbered to match a corresponding hole at thejobsite. This ensures that the right rough-in box 200 goes over thecorrect hole. Also, if lids 6 are removed or placed over the wrong hole,this can be easily inspected and corrected.

The rough-in box 200 with the lid 6 attached allows holes to be coveredprior to the pouring of concrete and stops leaks of concrete fromentering the holes. When the concrete is poured to form the floor of abuilding, the lid 6 prevents over-pour from the concrete and creates aperfect edge that is level with the concrete when the concretesolidifies. Thus, there are no obstructions on the floor because the lid6 will be flush with the concrete floor, allowing for the use ofdollies, manlifts, modular scaffolding, and designated walkways becausethe lid 6 is load bearing and capable of handling loads from heavymachines and equipment. As a result, fewer safety personnel are neededand work shutdowns are minimized and reduced.

The rough-in box 200 of the present invention is embedded in theconcrete floor, and only the lid 6 needs to be removed to completemechanical work. When the lids 6 are removed, the lids 6 can be easilystacked and removed all together.

While the present invention has been described above in terms ofspecific embodiments, it is to be understood that the invention is notlimited to these disclosed embodiments. Many modifications and otherembodiments of the invention will come to the mind of those skilled inthe art to which this invention pertains, and which are intended to beand are covered by both this disclosure and the appended claims. It isindeed intended that the scope of the invention should be determined byproper interpretation and construction of the appended claims and theirlegal equivalents, as understood by those of skill in the art relyingupon the disclosure in this specification and the attached drawings.

The single unitary piece 1 may be formed of any strong, tough material.For example, the side walls can be made from an aluminum sheet, steelsheet, high strength plastic, or any other material that can be formedinto the required shapes that has adequate strength.

The box or boxes 200 can be and fastened together by welding, rivets,screws 13, or any appropriate fastening method. The top will be leftopen. A flange 3 will be formed at the top of the boxes in aconfiguration as shown in FIG. 9. This flange 3 will serve to support abox lid 6 which will be installed in the box prior to placing concrete.The lid 6 will be flush with the surface of concrete after it is placed.

Different configurations 400 of boxes 200 may be made by joiningindividual boxes 200 of the required sizes, for example as shown inFIGS. 30-32. Typical configurations 400 can be a simple rectangularconfiguration 400 to form a straight trough or several boxes 200 may beconnected in a configuration 400 to form penetrations having shapesresembling the letter “L”, “T”, or a cruciform shape in plan view.

This embodiment of the present invention solves many of the laborinefficiencies and costs incurred when creating void spaces in slabs forconnecting plumbing fixtures. When the kits 100 for new boxes 200 orconfigurations 400 arrive on site, the boxes 200 are assembled prior toinstallation in the slab. They are delivered to the floor to be poured,and from there they are installed in a prearranged spot on the deck. Tofasten the boxes 200 or configurations 400 in place, they are simplynailed to the wooden deck and are then ready for the pouring process.Unlike previous methods, the boxes 200 in the present invention stay inthe concrete permanently this eliminates the need to grease or otherwiseprepare the box 20 or configuration 400 to be stripped out of the flooras is required with current methods. The boxes 200 or configurations 400are fitted with one or more covers 6 prior to placing the concrete sowork around the boxes 200 or configurations 400 can proceed fasterbecause workers do not have to worry about accidentally filling theboxes 200 or configurations 400 with concrete. The flush surfaceprovided by the lid(s) 6 of the box 200 or configuration 400 alsofacilitates screeding and finishing the concrete around the boxes. Thepresent invention eliminates the need to strip out rough-in boxes afterthe concrete is placed.

Current methods require the boxes to be pried out of the concrete toleave the appropriate void. Typically this removal of the boxes is doneafter the concrete fully sets, which is labor intensive, wastes time onthe construction site, and can be hazardous to the workers removing thebox. Additionally, concrete may overflow during placement and get insidethe boxes and this must be cleaned out by workers.

Another benefit of the present invention is the top flange 3, whichallows the lid 6 to sit flush with the surface of the concrete. Currentmethods require that plumbing boxes be covered with plywood hole coversthat are proud of the concrete surface. These plywood covers are atripping hazard and they interfere with the use of any wheeled devicesfor moving material around the floor.

According to conventional processes, the covers must be inspected dailyfor each floor. The present invention would drastically reduce thisrequirement, if not eliminate it completely, as the structuralcapabilities of the lid 6 would mean that the boxes 200 andconfigurations 400 would be able to withstand the loads and forcespresent on the site without failure. The reduction in inspectionfrequency would save on labor costs for the duration of the constructionphase.

When the general contractor takes control of the floor, they do not needto add the additional covers for the holes. The plumber and mechanicalservices can immediately take responsibility for the boxes and run thepipework or shafts needed.

The proposed method greatly improves existing methods by the fact thatit increases productivity and reduces labor costs, while also reducingthe potential trip or fall hazards present with existing methods, whichin turn reduces job stoppages from falls and injuries.

Another embodiment of the present invention will serve as a hole coverfor penetrations that have been conventionally formed in a concrete slabor any hole in any floor that needs to be covered securely. In thisembodiment, as shown in FIGS. 17-19, a frame of bent steel sections 12is fastened in the opening and provided with a top lid 6 with sufficientstrength to allow construction activities to safely proceed.

Each bent steel section 12 has a first extension 12 a, a secondextension 12 b, and a third extension 12 c. The first and thirdextensions 12 a, 12 c are approximately parallel to each other andextend in the same direction. The second extension 12 b extendsapproximately perpendicular to the first and third extensions 12 a, 12 cto connect the first and third extensions 12 a, 12 c with each other.

The height of the second extension 12 b (i.e., the up-down direction inFIG. 16) is preferably selected to correspond to a thickness of the toplid 6 that will be used so that a top of the lid 6 is flush with the topof the concrete floor 300—for example, approximately 0.5 inches. Thisreduces the chance of trips occurring while people work on the concretefloor 300.

Optionally, the first and third extensions 12 a, 12 c can includethrough holes 19, which allow the steel section 12 to easily be affixedto the concrete floor 300 by screws or bolts 13. The through holes 19can also be used to secure the lid 6 to the steel section 12 by screwsor bolts 13.

Preferably the steel sections 12 are placed around a hole in theconcrete floor 300 so that ends 12 d of two adjacent steel sections 12overlap. This increases the strength of the platform formed by the firstextensions 12 a on which the lid 6 rests.

LIST OF REFERENCE NUMBERS

-   1 single unitary piece-   2 perforations, through-holes, or slots-   2 a vertical arrays of perforations, through-holes, or slots 2-   2 b horizontal arrays of perforations, through-holes, or slots 2-   3 top flange-   3 a first extension of top flange 3-   3 b second extension of top flange 3-   4 bottom flange-   5 flat section (web)-   5 a inside surface-   5 b outside surface-   6 lid-   7 side walls-   8 a, 8 b ends of the single unitary piece 1-   9 lid handle-   10 corner piece-   11 end tab-   12 steel sections-   12 a first extension of steel sections 12-   12 b second extension of steel sections 12-   12 c third extension of steel sections 12-   12 d ends of steel sections 12-   13 screws-   14 fire rated rubber seal-   15 non-slip surface-   16 hydraulic hinges-   17 safety rail system-   18 bending lines-   19 through holes-   20 lanyard or tether-   46 slot for fireproofing-   100 rough-in box kit-   200 rough-in box-   300 concrete-   400 configuration

1. A rough-in box kit (100) for creating a rough-in box (200) to createa penetration in poured concrete flooring during the construction ofconcrete buildings, comprising: a single unitary piece (1) having: aflat section (5) that has: a top end; a bottom end opposite to the topend; an inside surface (5 a) located between the top end and the bottomend, and configured to form an inside surface of the rough-in box (200);and an outside surface (5 b) opposite to the inside surface (5 a), andconfigured to form an outside surface of the rough-in box (200); and atop flange (3) connected to and extending away from the top end of theflat section (5); perforations, through-holes, or slots (2) that areformed in the flat section (5); wherein the single unitary piece (1) isconfigured to be bent at locations corresponding to and lining up withthe perforations, through-holes, or slots (2) so as to form the rough-inbox (200).
 2. The rough-in box kit (100) of claim 1; wherein the topflange has: a first extension (3 a) that extends from the flat section(5) at approximately a 90° angle; and a second extension (3 b) thatextends from the first extension (3 a) at approximately a 90° angle. 3.The rough-in box kit (100) of claim 2; wherein the perforations,through-holes, or slots (2) are formed in the first extension (3 a). 4.The rough-in box kit (100) of claim 2 or 3; wherein the perforations,through-holes, or slots (2) are not formed in a distal end of the secondextension (3 b) opposite to and distal from the first extension (3 a).5. The rough-in box kit (100) of one of claims 2-4; wherein theperforations, through-holes, or slots (2) are formed in a proximal endof the second extension (3 b) adjacent and proximal to the firstextension (3 a).
 6. The rough-in box kit (100) of claim 2 or 3; whereinthe perforations, through-holes, or slots (2) are not formed in anyportion of the second extension (3 b).
 7. The rough-in box kit (100) ofone of claims 1-5; wherein the single unitary piece (1) additionallyhas: a bottom flange (4) connected to and extending away from the bottomend of the flat section (5) opposite to the top end of the flat section(5).
 8. The rough-in box kit (100) of claim 7; wherein the bottom flangeextends from the flat section (5) at approximately a 90° angle.
 9. Therough-in box kit (100) of claim 2; wherein the single unitary piece (1)additionally has: a bottom flange (4) connected to and extending awayfrom a bottom end of the flat section (5) opposite to the top end of theflat section (5); and wherein the bottom flange (4) extendsapproximately parallel to the a first extension (3 a) of the top flange(3).
 10. The rough-in box kit (100) of claim 7-9; wherein theperforations, through-holes, or slots (2) are not formed in a distal endof the bottom flange (4) opposite to and distal from the flat section(5).
 11. The rough-in box kit (100) of one of claims 7-9; wherein theperforations, through-holes, or slots (2) are formed in a proximal endof the bottom flange (4) adjacent and proximal to the flat section (5).12. The rough-in box kit (100) of claim 7-9; wherein the perforations,through-holes, or slots (2) are not formed in any portion of the bottomflange (4).
 13. The rough-in box kit (100) of one of claims 1-12;wherein the perforations, through-holes, or slots (2) form verticalarrays (2 a) in the flat section (5), each vertical array (2 a)extending in a vertical direction from the top end to the bottom end ofthe flat section (5).
 14. The rough-in box kit (100) of claim 13;wherein the vertical arrays (2 a) of perforations, through-holes, orslots (2) are spaced apart from each other in a horizontal directionperpendicular to the vertical direction so that the perforations,through-holes, or slots (2) additionally form horizontal arrays (2 b) inthe flat section (5) extending in the horizontal direction.
 15. Therough-in box kit (100) of one of claims 1-14; wherein the singe unitarypiece (1) made of an aluminum alloy.
 16. The rough-in box kit (100) ofone of claims 1-15, further comprising: a lid (6) formed configured tosupporting a weight of at least approximately 2,000 pounds when placedon top of the formed rough-in box (200).
 17. The rough-in box kit (100)of claim 16; wherein the lid (6) is formed of resin-impregnatedfiberglass.
 18. The rough-in box kit (100) of claim 17; wherein theresin-impregnated fiberglass is impregnated with an epoxy resin.
 19. Therough-in box kit (100) of claim 17; wherein the lid (6) comprises 18 to40 fiberglass layer strands of fiber.
 20. A rough-in box (200)comprising: the rough-in box kit (100) of one of claims 16-19; whereinthe single unitary piece (1) is bent at locations corresponding to andlining up with the perforations, through-holes, or slots (2) so as toform the rough-in box (200) with the lid (6) being flush with a pouredconcrete floor.
 21. The rough-in box (200) of claim 20, furthercomprising: a seal arranged between the lid (6) and the top flange (3)to create a waterproof or water-resistant seal when the lid (6) isarranged on the top flange (3).
 22. A method of constructing apenetration in a concrete floor (300), comprising: bending the singleunitary piece (1) of the rough-in box kit (100) of one of claims 1-19 atlocations corresponding to and lining up with the perforations,through-holes, or slots (2) so as to form a rough-in box (200); placingthe rough-in box (200) in a location on a formed deck corresponding to apredetermined location for the penetration in the concrete floor (300);pouring concrete around the rough-in box (200) to form the concretefloor (300).
 23. A method of constructing a penetration in a concretefloor (300), comprising: bending a single unitary piece (1) so as toform a rough-in box (200); placing the rough-in box (200) in a locationon a formed deck corresponding to a predetermined location for thepenetration in the concrete floor (300); placing a lid (6) on top of therough-in box (200); pouring concrete around the rough-in box (200) toform the concrete floor (300).
 24. The method according to claim 23;wherein one end (8 a) of the single unitary piece (1) is secured andaffixed to an opposite end (8 b) of the single unitary piece (1) to formthe rough-in box (200).
 25. The method according to claim 23 or 24,further comprising: cutting a top flange (3) of the single unitary piece(1) at multiple first locations; and cutting a bottom flange (4) of thesingle unitary piece at multiple second locations; wherein the singleunitary piece (1) is bent along multiple bending lines (18) so as toform a rough-in box (200), each bending line (18) extending from one ofthe first locations to one of the second locations.
 26. The methodaccording to claim 25, further comprising: wherein each bending line(18) corresponds to an array of perforations, through-holes, or slots(2) single unitary piece (1) so that the single unitary piece (1) isbent along the arrays of perforations, through-holes, or slots (2). 27.The method according to one of claim 23-26; wherein the concrete ispoured around the rough-in box (200) to form the concrete floor (300) sothat the lid (6) is flush with the poured concrete floor.
 28. A kit fora platform to securely hold a lid (6) over a penetration in a concretefloor (300), comprising: multiple single unitary pieces (12) having: afirst extension (12 a) extending along a first plane; a second extension(12 b) extending from an end of the first extension (12 a) along asecond plane intersecting with the first plane; and a third extension(12 c) extending from an end of the second extension (12 b) opposite tothe first extension (12 a) along a third plane approximately parallel tothe first plane.
 29. The kit according to claim 28: wherein a height ofthe second extension (12 b) extending between the first and thirdextensions (12 a, 12 c) in a direction perpendicular to the first planecorresponds to a thickness dimension of a lid (6).
 30. The kit accordingto claim 28 or 29: wherein at least one of the first and thirdextensions (12 a, 12 c) includes through holes (19), each through hole(19) being configured to accept a screw or bolt (13) so that themultiple single unitary pieces (12) can be screwed or bolted to theconcrete floor (300).
 31. A platform for securely holding a lid (6) overa penetration in a concrete floor (300), comprising: the multiple singleunitary pieces (12) of the kit according to one of claims 28-30; whereineach single unitary piece (12) is arranged around an edge of thepenetration so that at least a portion of an end (12 d) of each singleunitary piece (12) overlaps with at least a portion of an end (12 d) ofan adjacent single unitary piece (12).